Haynes Ford Mondeo 1993 to 1999 Service and Repair Manual (K to T Registration) Petrol [1923] 1859605133, 9781859605134

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Contents REPAIRS & OVERHAUL Engine and associated systems Four-cylinder (Zetec) engine in-car repair procedures

Page 2Ae1

Fuel and exhaust systems

V6 =~* (Duratec) ~*~ engine*”* in-carrepair ~C~ procedur C~C es.~C*C~C”C”::”:::CCO age 2Bed Engine ==*= removal ~S*é and “‘“‘ overhaul procedur =~*” es. *”S”S”S”S”*~*~*~*~*~;”;” Rage 2eWd Cooling, =2=heating 2=2 and=~= airconditioni ~S* ng systems. é“‘=CS*‘“‘ ar

edt

General repair procedures Jacking and vehicle support

“

Radio/cassette anti-theft system - precaution

ar

Tools and working facilities

ty

MOT test checks

,

Bs

Page

REFe1

Page

REFe2

Page

REFe3

Page

REFe4

Page

REFe5

Page

REFe5

Page

REFe6

Page

REF*8

Fault finding

Page REFe12

Glossary of technical terms

Page REFe19

Index

Page REF*24

oo4 INtroduction Introduced in March 1993, the Ford Mondeo models are available in four-door Saloon, five-door Hatchback and five-door Estate configurations. All feature a high standard of equipment, with driver/passenger safety in accidents being a particularly high design priority; all models are fitted with features such as side impact bars in all doors, ‘anti-submarine’ seats combined with seat belt pretensioners, and an airbag fitted to the steering wheel. Vehicle security is enhanced, with an in-built alarm system and engine immobiliser

The vacuum servo-assisted brakes are disc at the front, with drums at the rear on most models; disc rear brakes and an electronicallycontrolled Anti-lock Braking System (ABS) are available on some models, with a Traction Control System (TCS) available as a further option where ABS is fitted.

being fitted as standard, as well as double-locking doors with shielded

locks, and security-coded audio equipment. The Zetec 16-valve four-cylinder petrol engine is a new design, available in 1.6, 1.8 and 2.0 litre capacities. It is controlled by a

sophisticated engine management system, which combines multipoint sequential fuel injection and distributorless ignition systems with evaporative emissions control, exhaust gas recirculation and a three-

way regulated catalytic converter (with a pulse-air system for rapid warm-up) to ensure that the vehicle complies with the most stringent of the emissions control standards currently in force, and yet provides the

levels of performance and fuel economy expected. In September 1994, the petrol engine range was completed, with the

introduction of the 2.5 litre Duratec V6 engine. Designed and built in the USA, where it is fitted to the parallel Ford Contour range, this 24valve transverse design is particularly light and compact. The range received a major facelift in October 1996, with heavilymodified front and rear styling reflecting the ‘edge’ design philosophy pioneered by the Ka. The already-acclaimed suspension and steering were further improved, and the latest EEC-V engine management system was fitted to all models The transversely-mounted engine drives the front roadwheels through either a five-speed manual transmission with a cable- or hydraulically-operated clutch, or through an electronically-controlled four-speed automatic transmission. The fully-independent suspension is by MacPherson strut on all four roadwheels, located by transverse lower arms at the front, and by transverse and trailing arms at the rear; anti-roll bars are fitted at the

1993 Mondeo 1.8 GLX Estate

Provided that regular servicing is carried out in accordance with the manufacturer’s recommendations, the Mondeo should prove a reliable and economical car. The engine compartment is well-designed, and most of the items needing frequent attention are easily accessible.

Your Ford Mondeo manual

front and rear. The Estate rear suspension is of a different design, to

The aim of this manual is to help you get the best value from your

give maximum loadspace inside the vehicle, with self-levelling suspension units available as an option. On some models, the suspension is electronically-controlled through an Adaptive Damping

vehicle. It can do so in several ways. It can help you decide what work

System. The steering is power-assisted, the pump being belt-driven from the

engine, and the rack-and-pinion steering gear mounted behind the engine.

must be done (even should you choose to get it done by a garage). It will also provide information on routine maintenance and servicing, and give a logical course of action and diagnosis when random faults

occur. However, it is hoped that you will use the manual by tackling the work yourself. On simpler jobs it may even be quicker than booking the car into a garage and going there twice, to leave and collect it. Perhaps most important, a lot of money can be saved by avoiding the costs a garage must charge to cover its labour and overheads.

The manual has drawings and descriptions to show the function of the various components so that their layout can be understood. Tasks are described and photographed

in a clear step-by-step sequence.

The illustrations are numbered by the Section number and paragraph number to which they relate - if there is more than one illustration per

paragraph, the sequence is denoted alphabetically. References to the ‘left’ or ‘right’ of the vehicle are in the sense of a person in the driver’s seat, facing forwards.

Acknowledgements Thanks are due to Champion Spark Plug, who supplied the illustrations showing spark plug conditions, and to Duckhams Oils, who provided lubrication data. Thanks are also due to Draper Tools Limited, who provided some of the workshop tools, and to all those people at Sparkford who helped in the production of this manual. We take great pride in the accuracy of information given in this 1997 Mondeo V6 Ghia Saloon

manual, but vehicle manufacturers make alterations and design changes during the production run of a particular vehicle of which they do not inform us. No liability can be accepted by the authors or publishers for loss, damage or injury caused by any errors in, or omissions from, the information given.

Safety first! o-s Working on your car can be dangerous. This page shows just some of the potential risks and hazards, with the aim of creating a safety-conscious attitude.

e Mains voltage is also dangerous. Make sure that any mains-operated equipment is correctly earthed. Mains power points should be protected by a residual current device

Special hazards

General hazards

(RCD) circuit breaker.

° This extremely corrosive acid is formed

Scalding ¢ Don’t remove the radiator or expansion tank cap while the engine is hot. e Engine oil, automatic transmission fluid or power steering fluid may also be dangerously hot if the engine has recently been running.

Burning e Beware of burns from the exhaust system and from any part of the engine. Brake discs and drums can also be extremely hot

immediately after use.

Crushing e When working under or near a raised vehicle, always supplement the jack with axle

stands, or use

Fume or gas intoxication e Exhaust fumes are poisonous; they often contain carbon monoxide, which is rapidly fatal if inhaled. Never run the engine ina confined space such as a garage with the doors shut. e Fuel vapour is also poisonous, as are the vapours from some cleaning solvents and paint thinners.

Poisonous or irritant substances e Avoid skin contact with battery acid and with any fuel, fluid or lubricant, especially antifreeze, brake hydraulic fluid and Diesel fuel. Don’t syphon them by mouth. If such a substance is swallowed or gets into the eyes,

Hydrofluoric acid when certain types of synthetic rubber, found in some O-rings, oil seals, fuel hoses etc, are exposed to temperatures above 400°C. The rubber changes into a charred or sticky substance containing the acid. Once formed, the acid remains dangerous for years. If it gets onto the skin, it may be necessary to amputate the limb concerned. e When dealing with a vehicle which has suffered a fire, or with components salvaged from such a vehicle, wear protective gloves

and discard them after use.

The battery e Batteries contain sulphuric acid, which attacks clothing, eyes and skin. Take care when topping-up or carrying the battery. e The hydrogen gas given off by the battery is highly explosive. Never cause a spark or allow a naked light nearby. Be careful when connecting and disconnecting battery chargers or jump leads.

seek medical advice. e Prolonged contact with used engine oil can

Air bags

venture under a car which is only supported by a jack.

cause skin cancer. Wear gloves or use a barrier cream if necessary. Change out of oilsoaked clothes and do not keep oily rags in your pocket.

e Air bags can cause injury if they go off accidentally. Take care when removing the steering wheel and/or facia. Special storage instructions may apply.

Diesel injection equipment

drive-on

ramps. Never

¢ Take care if loosening or tightening high-

e Air conditioning refrigerant forms a

torque nuts when the vehicle is on stands.

poisonous gas if exposed to a naked flame

Initial loosening and final tightening should be

(including a cigarette). It can also cause skin

done with the wheels on the ground.

burns on contact.

Fire

Asbestos

e Fuel is highly flammable; fuel vapour is

e Asbestos dust can cause cancer if inhaled or swallowed. Asbestos may be found in gaskets and in brake and clutch linings. When dealing with such components it is safest to assume that they contain asbestos.

explosive. e Don’t let fuel spill onto a hot engine. e Do not smoke or allow naked lights

(including pilot lights) anywhere near a vehicle being worked on. Also beware of

e Diesel injection pumps supply fuel at very high pressure. Take care when working on the fuel injectors and fuel pipes. Warning: Never expose the hands, face or any other part of the body to injector spray; the fuel can penetrate the skin with potentially fatal results.

creating sparks e Fuel vapour is heavier than air, so don’t

Remember...

work on the fuel system with the vehicle over an inspection pit.

DO

DON’T

° Do use eye protection when using power tools, and when working under the vehicle.

e Don’t attempt to lift a heavy component which may be beyond your capability — get assistance.

(electrically or by use of tools).

e Another cause of fire is an electrical overload or short-circuit. Take care when repairing or modifying the vehicle wiring. e Keep a fire extinguisher handy, of a type

suitable for use on fuel and electrical fires.

Electric shock @ Ignition HT voltage can be dangerous, especially to

my ay a

people with heart problems ora pacemaker. Don’t work on or near the ignition system with

the engine running or the ignition switched on.

‘

e Do wear gloves or use barrier cream to

protect your hands when necessary.

e Don’t rush to finish a job, or take

e Do get someone to check periodically that all is well when working alone on the vehicle.

¢ Don’t use ill-fitting tools which may slip and cause injury.

© Do keep loose clothing and long hair well out of the way of moving mechanical parts.

¢ Don’t leave tools or parts lying around where someone can trip over them. Mop

e Do remove rings, wristwatch etc, before working on the vehicle — especially the electrical system.

e Don’t allow children or pets to play in or

e Do ensure that any lifting or jacking equipment has a safe working load rating adequate for the job.

unverified short cuts.

up oil and fuel spills at once. near a vehicle being worked on.

o¢ Roadside repairs The following pages are intended to help in dealing with common roadside emergencies and breakdowns. You will find more detailed fault finding information at the back of the manual, and repair information in the main chapters.

If your car won’t start even though the starter motor turns as normal

If your car won’t start and the starter motor doesn’t turn If it’s a model with automatic transmission, make sure the

selector is in ‘P’ or ‘N’. Open the bonnet and make sure that the battery terminals are clean and tight. Switch on the headlights and try to start the engine. If the headlights go very dim when you're trying to start, the battery is probably flat. Get out of trouble by jump starting (see next page) using a friend’s car.

Check the security and condition of the battery connections.

Is there fuel in the tank? Is there moisture on electrical components under the

bonnet? Switch off the ignition, then wipe off any obvious dampness with a dry cloth. Spray a water-repellent aerosol product (WD-40 or equivalent) on ignition and fuel system electrical connectors like those shown in the photos. Pay special attention to the ignition coil wiring connector and HT leads.

Check the wiring plug connections to the ignition coil.

Check the HT lead connections at the ignition coil.

bas

Check that the HT leads are securely D connected to the spark plugs (where possible).

Check that electrical connections are secure (with the ignition switched off). Spray the connector plugs with a water-dispersant spray like WD40 if you suspect a problem due to damp.

= Check that none of the engine compartment fuses have blown.

Roadside repairs o-7 PINs

Jump starting

Jump starting will get you out of trouble, but you must correct

HINT whatever made the battery go — flat in the first place. There are _ three possibilities: “@ The battery has been drained by repeated attempts to start, or by leaving the lights on. The charging system is not working properly (alternator drivebelt slack

or broken, alternator wiring fault or

When jump-starting a car using a booster battery, observe the following precautions:

v

v_

Ensure that all electrical equipment (lights, heater, wipers, etc) is switched off.

¥Y

Take note of any special precautions printed on the battery case.

alternator itself faulty). The battery itself is at fault (electrolyte low, or battery worn out).

5| Connect one end of the red jump lead to the positive (+) terminal of the flat battery eee

ee ee ee

ee

Before connecting the booster battery, make sure that the ignition is switched off.

vY

Make sure that the booster battery is the same voltage as the discharged one in the vehicle.

vy

lf the battery is being jump-started from the battery in another vehicle,

the two vehicles MUST NOT TOUCH each other. Vv

2

Connect the other end of the red lead to the positive (+) terminal of the booster

Make sure that the transmission is in neutral (or PARK, in the case of automatic transmission).

3

Connect one end of the black jump lead to the negative (-) terminal of the booster battery

4

Connect the other end of the black jump lead to a bolt or bracket on the engine

battery. I j [ i

a | as

block, well away from the battery, on the

vehicle to be started. Make sure that the jump leads will not come into contact with the fan, drivebelts or other moving parts of the engine.

eee oe ee ee ee ee

Start the engine using the booster battery and run it at idle speed. Switch on the lights, rear window demister and heater blower motor, then disconnect the jump leads in the reverse order of connection. Turn off the lights etc.

os Roadside repairs Wheel changing Warning: Do not change a wheel in a situation where you risk being hit by another vehicle. On busy roads, try to stop in a layby or a gateway. Be wary of passing traffic while changing the wheel - it is easy to become distracted by the job in hand.

Preparation []

When a puncture occurs, stop as soon as it is safe to do so. Park on firm level ground, if possible, and well out of the way of other traffic. Use hazard warning lights if necessary.

If you have one, use a warning triangle to alert other drivers of your presence. Apply the handbrake and engage first or reverse gear (or Park on models with automatic transmission.

Chock the wheel diagonally opposite the one being removed — a couple of large stones will do for this. If the ground is soft, use a flat piece of wood to spread the load under the jack.

Changing the wheel

1 The spare wheel and tools are stored in the luggage compartment.

Fold back the

Unscrew the retainer, and lift the spare

Unscrew the retainer, and lift the jack and

wheel out.

wheel brace out of the wheel well. The

floor covering and lift up the cover panel.

screw-in towing eye is also provided in the wheel well.

4 Where applicable, using the flat end of the wheelbrace, prise off the centre cover or wheel trim for access to the wheel nuts. Slacken each wheel nut by a half turn,

using the wheelbrace. If the bolts are too tight,

On models with side skirts, remove the jacking point covers by pressing upwards and outwards. Use the jacking point nearest the punctured wheel. Locate the jack

head

6 Unscrew the wheel nuts, noting which way round they fit (tapered side inwards), and remove the wheel.

at the point in the lower sill flange

DON’T stand on the wheelbrace to undo them __ indicated by the indentation in the sill (don’t

- Call for assistance from one of the motoring organisations.

jack the vehicle at any other point of the sill). Turn the jack handle clockwise until the wheel is raised clear of the ground.

Finally... Remove the wheel chocks.

Stow the punctured wheel and tools back in the luggage compartment, and secure them in position.

|] Fit the spare wheel, and screw on the nuts.

Lightly tighten the nuts with the wheelbrace, then lower the vehicle to the ground.

Securely tighten the wheel nuts, then refit the wheel trim or centre cover, as applicable.

Check the tyre pressure on the wheel just fitted. If it is low, or if you don’t have a pressure gauge with you, drive slowly to the nearest garage and inflate the tyre to the right pressure. The wheel nuts should be slackened and retightened to the specified torque at the earliest possible opportunity. Have the punctured wheel repaired at the earliest opportunity, or another puncture will leave you stranded.

Roadside repairs os Identifying leaks Puddles on the garage floor or drive, or obvious wetness under the bonnet or underneath the car, suggest a leak that needs investigating. It can sometimes be difficult to decide where the leak is coming from, especially if the engine bay is very dirty already. Leaking oil or fluid can also be blown rearwards by the passage of air under the car, giving a false impression of where the problem lies.

Warning: Most automotive oils and fluids are poisonous. Wash them off skin, and change out of contaminated clothing, without delay.

HAYNES

The smell of a fluid leaking from the car may provide a HINT clue to what’s leaking. Some fluids are distictively coloured. It may help to clean the car carefully and to park it over some clean paper overnight as an aid to locating the

source of the leak. Remember that some leaks may only occur while the engine is running.

Sump oil

Oil from filter

Gearbox oil

Engine oil may leak from the drain plug...

Oli from the base of the oil filter.

Gearbox oil can leak from the seals at the

inboard ends of the driveshafts.

Antifreeze

Brake fluid

Power steering fluid

Leaking antifreeze often leaves a crystalline

A leak occurring at a wheel is almost certainly brake fluid.

Power steering fluid may leak from the pipe connectors on the steering rack.

deposit like this.

Towing When all else fails, you may find yourself having to get a tow home - or of course you may be helping somebody else. Long-distance recovery should only be done by a garage or breakdown service. For shorter distances, DIY towing using another car iS easy enough, but observe the following points: (J Use

a

proper

tow-rope

-

they

are

not

expensive. The vehicle being towed must display an ‘ON TOW’ sign in its rear window.

ZC Always turn the ignition

key to the ‘on’

position when the vehicle is being towed, so that the steering lock is released, and that the direction indicator and brake lights will work.

CJ On early models, the front towing eye is below or behind a cover in the front bumper. The rear towing eye is located below the rear bumper, on all early models and later Estates. LJ On later models, the front towing eye is of the

screw-in type, and is found in the spare wheel well. The towing eye screws into the threaded hole below the right-hand

headlight, accessible

after prising out a cover in the bumper, and has a left-hand thread - ie it screws in anti-clockwise (see illustration). On later Saloons and Hatchbacks,

a similar arrangement

is used for

the rear towing eye. LJ Before being towed, release the handbrake and make sure the transmission is in neutral. L] Note that greater-than-usual pedal pressure will be required to operate the brakes, since the vacuum servo unit is only operational with the engine running. LJ The driver of the car being towed must keep the tow-rope taut at all times to avoid snatching. CL] Make sure that both drivers know the route before setting off.

Only drive at moderate speeds, and keep the distance towed

to a minimum.

Drive smoothly,

and allow plenty of time for slowing down junctions. On

models

with

automatic

at

transmission,

special precautions apply. If in doubt, do not tow, or transmission damage may result.

Front towing eye

o-10 Weekly checks Introduction There are some very simple checks which

Keeping

an eye on tyre condition

and

need only take a few minutes to carry out, but which could save you a lot of inconvenience and expense.

pressures, will not only help to stop them wearing out prematurely, but could also save yout life.

These "Weekly checks" require no great skill or special tools, and the small amount of time they take to perform could prove to be very well spent, for example;

Many breakdowns are caused by electrical problems. Battery-related faults are particularly common, and a quick check on a regular basis will often prevent the majority of these.

lf your car develops a brake fluid leak, the first time you might know about it is when your brakes don't work properly. Checking the level regularly will give advance warning of this kind of problem. If the oil or coolant levels run low, the cost

of repairing any engine damage will be far greater than fixing the leak, for example.

Underbonnet check points ¢q Four-cylinder engine Engine oil level dipstick Engine oil filler cap Coolant expansion tank

Brake (and clutch) fluid reservoir

Power steering fluid reservoir Screen washer fluid reservoir Battery OaQndPY omm

V6 engine Engine oil level dipstick Engine oil filler cap

Coolant expansion tank Brake (and clutch) fluid reservoir

Power steering fluid reservoir Screen washer fluid reservoir

mm GOWN> omBattery A

Weekly checks 0«11 Engine oil level Before you start V Make sure that your car is on level ground. V Check the oil level before the car is driven,

or at least 5 minutes after the engine has been switched off. MYNANiasa

HINT

/f

the

oil

is

checked

immediately after driving the vehicle, some of the oil will remain in the upper engine

components,

resulting in an inaccurate

1

The dipstick top is brightly coloured for

easy

reading on the dipstick!

identification

check points’ on

(see ‘Underbonnet page

0°10

for exact

location). Withdraw the dipstick. Using a clean

The correct oil Modern engines place great demands on their

rag or paper towel, remove dipstick.

all oil from the

2

Insert the clean dipstick into the tube as far as it will go, then withdraw it again. Note the oil level on the end of the dipstick, which should be between the ‘MAX’ and ‘MIN’ marks. If the oil level is only just above, or below, the ‘MIN’ mark, topping-up is required.

oil. It is very important that the correct oil for your car is used (See “Lubricants, fluids and tyre pressures” on page 0e16).

Car Care @ If you have to add oil frequently, you should check whether you have any oil leaks. Place some clean paper under the car overnight, and check for stains in the morning. If there are no leaks, the engine may be burning oil

(see “Fault Finding”). @ Always

maintain

the

level

between

the

ZL

upper and lower dipstick marks (see photo 2). If the level is too low severe engine damage may occur. Oil seal failure may result if the engine is overfilled by adding too much oil.

Oil is added through the filler cap. Lift off

4

.

. and top-up the level; a funnel may be

useful in reducing spillage. Add the oil

or unscrew the cap...

slowly, checking the level on the dipstick often, and allowing time for the oil to fall to the sump. Add oil until the level is just up to the ‘MAX’ mark on the dipstick - don’t overfill (see ‘Car care’ left).

Power steering fluid level Before you start: V Park the vehicle on level ground. V Set the steering wheel straight-ahead. V The engine should be turned off.

The reservoir is located at the right-hand rear corner of the engine compartment. The fluid level is visible through the reservoir body; when the system is at operating temperature, the level should be up to the ‘MAX’ mark on the side of the reservoir.

MYNaNiasy

HINT

2

For

the

accurate,

check

to

be

the steering must

not be turned once the engine has been stopped.

If topping-up is required, wipe clean the area around the reservoir filler neck and unscrew the filler cap from the reservoir.

Safety First! @ The need for frequent topping-up indicates a leak, which should be_ investigated immediately.

When topping-up, use the specified type

of fluid and do not overfill the reservoir. When the cap.

the level is correct, securely refit

o-12 Weekly checks Brake (and clutch*) fluid level *On models with a hydraulically-operated clutch, this information is also applicable to the clutch fluid level Warning: @ Brake fluid can harm your eyes and damage painted

surfaces,

so

caution when pouring it.

use _ extreme handling

and

@ Do not use fluid that has been standing open for some time, as it absorbs moisture from the air, which can cause a dangerous loss of braking effectiveness. The brake fluid reservoir is located on the left-hand side of the engine compartment.

e Make sure that your car is on level ground. e The fluid level in the reservoir will drop slightly as

The ‘MAX’ and ‘MIN’ marks are indicated on the side of the reservoir. The fluid level must be kept between the marks at all times.

the brake pads wear down, but the fluid level must never be allowed to drop

below the “MIN” mark.

Safety First! @ If the reservoir requires repeated toppingup this is an indication of a fluid leak somewhere in the system, which should be investigated immediately. @ If a leak is suspected, the car should not be driven until the braking system has been

checked. Never take any risks where brakes are concerned.

3

If topping-up is necessary, first wipe clean the area around the filler cap to prevent dirt entering the hydraulic

system,

then unscrew

and

remove

the

reservoir cap. Inspect the reservoir; if the fluid is dirty, the hydraulic system should be

Carefully add fluid, taking care not to spill it onto the surrounding components. Use only the specified fluid; mixing different types can cause damage to the system. After topping-up to the correct level, securely refit the cap and wipe off any spilt fluid.

drained and refilled (see Chapter 1).

Screen washer fluid level* * The underbonnet reservoir also serves the tailgate washer, and the headlight washers, where fitted. Screenwash

additives

not

only

keep

the

winscreen clean during foul weather, they also prevent the washer system freezing in cold

weather - which is when you are likely to need it most. Don’t top up using plain water as the screenwash will become too diluted, and will

%

The screen washer fluid reservoir filler neck is located in the right-hand front

corner

of the

behind the headlight.

engine

compartment,

freeze during cold weather. On no account use coolant antifreeze in the washer system this could discolour or damage paintwork.

a

The screen washer level cannot easily be

seen. Remove the filler cap, and look down the filler neck - if fluid is not visible, topping-up may be required.

When topping-up the reservoir, add a screenwash additive in the quantities recommended on the bottle.

Weekly checks o«13 Coolant level Warning:

DO NOT attempt

to

remove the expansion tank pressure cap when the engine is hot, as there is a very great

risk of scalding. Do not leave open containers of coolant about, as it is poisonous.

Car Care @ With a sealed-type cooling system, adding coolant should not be necessary on a regular basis. lf frequent topping-up is required, it is likely there is a leak. Check the radiator, all hoses and joint faces for signs of staining or wetness, and rectify as necessary.

@ It is important that antifreeze is used in the cooling system all year round, not just during

The coolant level varies with the temperature of the engine, and is visible through the expansion tank. When the engine is cold, the coolant level should be

2

... and the ‘MIN’ mark on the front of the reservoir. When the engine is hot, the level may rise slightly above the ‘MAX’

mark.

between the ‘MAX’ mark on the side...

the winter months. Don’t top-up with water alone, as the antifreeze will become too

diluted.

If topping up is necessary, wait until engine is cold. Slowly unscrew expansion tank cap, to release pressure present in the cooling system, remove it. 3

the Add a mixture of water and antifreeze to the the expansion tank until the coolant level any is halfway between the level marks. Refit and _ the cap and tighten it securely.

Wiper blades

oe

Check the condition of the wiper blades;

if they are cracked or show any signs of deterioration, or if the glass swept area is smeared, renew them. Wiper blades should be renewed annually, regardless of their apparent condition. APN

/f smearing is still a problem despite fitting new wiper HINT blades, try cleaning the windscreen with neat screenwash additive or methylated spirit.

To remove a windscreen wiper blade, pull

Don’t forget to check the tailgate wiper

the arm fully away from the screen until it blade as well (where applicable). Remove locks. Swivel the blade through 90°, the blade using a similar technique to the press the locking tab with your fingers and _ windscreen wiper blades. slide the blade out of the arm’s hooked end.

o14 Weekly checks Tyre condition and pressure It is very important

that tyres are in good

condition, and at the correct pressure - having a tyre failure at any speed is highly dangerous.

Tyre wear is influenced by driving style - harsh braking and acceleration, or fast cornering, will all produce more

rapid tyre wear. As a

general rule, the front tyres wear out faster than the rears. Interchanging the tyres from

front to rear ("rotating" the tyres) may result in more even wear. However, if this is completely effective, you may have the expense of replacing all four tyres at once! Remove any nails or stones embedded in the tread before they penetrate the tyre to cause deflation. If removal of a nail does reveal that

the tyre has. been punctured, refit the nail so that its point of penetration is marked. Then immediately change the wheel, and have the tyre repaired by a tyre dealer. Regularly check the tyres for damage in the form of cuts or bulges, especially in the sidewalls. Periodically remove the wheels, and clean any dirt or mud from the inside and outside surfaces. Examine the wheel rims for signs of rusting, corrosion, or other damage. Light alloy wheels are easily damaged by

New tyres should be balanced when they are fitted, but it may become necessary to rebalance them as they wear, or if the balance weights fitted to the wheel rim should fall off. Unbalanced tyres will wear more quickly, as will the steering and suspension components. Wheel imbalance is normally signified by vibration,

particularly

at a certain

speed

"kerbing" whilst parking; steel wheels may also become dented or buckled. A new wheel is very often the only way to overcome severe

(typically around 50 mph). If this vibration is felt only through the steering, then it is likely that just the front wheels need balancing. If, however, the vibration is felt through the whole car, the rear wheels could be out of balance. Wheel balancing should be carried

damage.

out by a tyre dealer or garage.

“

Tread Depth - visual check The original tyres have tread wear safety

bands (B), which will appear when the tread depth reaches approximately 1.6 mm. The band positions are indicated by a triangular

Tyre Pressure Check

Tread Depth - manual check Alternatively,

tread

wear

can

be

monitored with a simple, inexpensive device known as a tread depth indicator gauge.

mark on the tyre sidewall (A).

Check the tyres pressures been used,

the tyre pressures regularly with cold. Do not adjust the tyre immediately after the vehicle has or an inaccurate setting will result.

Tyre pressures are shown on page 0°16.

Tyre tread wear patterns

Shoulder Wear

Centre Wear

Uneven Wear

Underinflation (wear on both sides) Under-inflation will cause overheating of the tyre, because the tyre will flex too much, and the tread will not sit correctly on the road surface. This will cause a loss of grip and excessive wear, not to mention the danger of sudden tyre failure due to heat build-up.

Overinflation Over-inflation will cause rapid wear of the centre part of the tyre tread, coupled with reduced grip, harsher ride, and the danger of shock damage occurring in the tyre casing. Check and adjust pressures

Front tyres may wear unevenly as a result of wheel misalignment. Most tyre dealers and garages can check and adjust the wheel alignment (or "tracking") for a modest charge. Incorrect camber or castor

Check and adjust pressures Incorrect wheel camber (wear on one side) Repair or renew suspension parts

If you sometimes have to inflate your car’s

Hard cornering Reduce speed!

tyres to the higher pressures

specified for

maximum load or sustained high speed, don’t forget to reduce the pressures to normal afterwards.

Repair or renew suspension parts Malfunctioning suspension

Repair or renew suspension parts Unbalanced wheel Balance tyres Incorrect toe setting Adjust front wheel alignment Note: The feathered edge of the tread which typifies toe wear is best checked by feel.

Weekly checks o«15 Battery Caution: Before carrying out any work on the

vehicle battery, read the precautions given in "Safety first" at the start of this manual. V Make sure that the battery tray is in good condition, and that the clamp is tight. Corrosion on the tray, retaining clamp and the battery itself can be removed with a solution of water and baking soda. Thoroughly rinse all

cleaned areas with water. Any metal parts damaged by corrosion should be covered with a zinc-based primer, then painted. Vv Periodically (approximately every

=.

months), check the charge condition of the battery as described in Chapter 5A.

The battery is located in the left-hand front corner of the engine compartment. The exterior of the battery should be inspected periodically for damage such as a

Vv |f the battery is flat, and you need to jump

cracked case or cover.

three

start your vehicle, see Roadside Repairs.

Battery corrosion can be kept to a minimum by applying a layer of

petroleum jelly to the clamps and terminals after they are reconnected.

3

...as well as the battery cable clamps

If corrosion (white, fluffy deposits) is evident, remove the cables from the battery terminals, clean them with a small wire brush, then refit them. Automotive stores sell a useful tool for cleaning the battery post...

Bulbs and fuses V Check all external lights and the horn. Refer to the appropriate Sections of Chapter 12 for - details if any of the circuits are found to be

Check the tightness of battery clamps to ensure good electrical connections. You should not be able to move them. Also check each cable for cracks and frayed conductors.

MPN

¥v Visually check all accessible wiring connectors, harnesses and retaining clips for security, and for signs of chafing or damage.

/f you need to check your brake lights and indicators unaided, back up to a wall or garage door and operate the lights. The reflected light should show if they are working properly.

inoperative.

1 If a single indicator light, stop-light or headlight has failed, it is likely that a bulb has blown and will need to be replaced.

Refer to Chapter 12 for details. If both stoplights have failed, it is possible that the switch has failed (see Chapter 9).

2? If more than one indicator light or tail light has failed, it is likely that either a fuse has blown or that there is a fault in the circuit (see Chapter 12). The main fusebox is located

below the facia panel on the passenger’s side,

and

is accessed

by

a

lever

behind

the

glovebox. The auxiliary fusebox is located

next to the battery - unclip and remove the cover for access.

3

To replace a blown fuse, simply pull it out

and fit a new fuse of the correct rating (see Chapter 12). If the fuse blows again, it is important that you find out why - a complete checking procedure is given in

Chapter 12.

ois Lubricants, fluids and tyre pressures Lubricants and fluids Multigrade engine oil, viscosity SAE 5W/30, 5W/40, 10W/30 or 10W/40*, to Ford specification WSS-M2C912-A1, API SH

or ACEA A1-96 (Duckhams QXR Premium Petrol Engine Oil) Motorcraft Super Plus 4 antifreeze to Ford specification ESD-M97B49-A, or Motorcraft Super Plus 2000 antifreeze to Ford specification WSS-M97B44-D

(Duckhams Antifreeze and Summer Coolant) Gear oil to Ford specification WSD-M2C200B

Manual transmission ................ Automatic transmission..............

Automatic transmission fluid to Ford specification

ESP-M2C 166-H (Duckhams ATF Autotrans III) Brake (and clutch) hydraulic system

Power steering

Hydraulic fluid to Ford specification ESDM 6C57-A,

...

Super DOT 4 (Duckhams Universal Brake & Clutch Fluid) Automatic transmission fluid to Ford specification

................00008.

ESP-M2C 166-H (Duckhams ATF Autotrans III) *Note: Do not use engine oils of higher viscosity, eg 15W/40,

15W/50 or 20W/50, as doing so may lead to engine running problems. Certain oil

additives may increase effective oil viscosity, and are not recommended in these engines.

Choosing your engine oil Engines need oil, not only to lubricate moving

e Cleaning the engine internally

parts and minimise wear, but also to maximise power output and to improve fuel economy. By introducing a simplified and improved

Good quality engine oils clean the inside of

range of engine oils, Duckhams has taken away the confusion and made it easier for you to choose the right oil for your engine.

HOW ENGINE OIL WORKS e Beating friction Without oil, the moving surfaces inside your engine will rub together, heat up and melt,

your engine, collecting and dispersing combustion deposits and controlling them until they are trapped by the oil filter or flushed out at oil change.

OIL CARE - FOLLOW THE CODE To handle and dispose of used engine oil safely, always: e Avoid skin contact

with

creates a film which separates these moving parts, preventing wear and heat build-up.

¢ Cooling hot-spots

a coolant, transferring heat from the hot-spots to the sump.

engine

oil.

ENGINE OILS

quality oil for complete

a premium

reassurance,

we

recommend synthetic formula Duckhams QXR Premium Engine Oils. For the driver who requires a straightforward quality engine oil, we recommend Duckhams Hypergrade Engine Oils. For further information and advice, call the

Duckhams UK Helpline on 0800 212988.

Repeated or prolonged contact can be harmful. e Dispose of used oil and empty packs in a responsible manner in an authorised disposal site.

quickly causing the engine to seize. Engine oil

Temperatures inside the engine can exceed 1000° C. The engine oil circulates and acts as

used

DUCKHAMS

For the driver who demands

,,

Call 0800 663366 to find

66

the one nearest to you. Never tip oil down drains or onto the ground.

Tyre pressures Tyre pressures (tyres cold): Normally-laden (up to 3 people) ....... Fully-laden

Front

2.1 bar (31 psi) 2.4 bar (35 psi)

Rear

2.1 bar (31 psi) 2.8 bar (41 psi)

Note 1: Pressures apply to original-equipment tyres, and may vary if any other make of tyre is fitted; check with the tyre manufacturer or supplier for the correct pressures if necessary. Note 2: For sustained high speeds above 100 mph (160 km/h), increased pressures are necessary. Consult the driver’s handbook supplied with the vehicle.

Chapter 1 Routine maintenance and servicing Contents Aigeoncitioning) SyStemiCneC keane cn eveatepess oo cars cased yeleieiers «m= 10 AUGTUECGEIEMOENTNEMEWAL

raveseuens aiciepepoed- cue oir one © silosede whieny weg, ausliouer 2A.

Expansion tank pressure cap check Evelitiltenremewallltesmects

cence

............-..2++.+++05: 30

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Gin

serena theaters sneer iaseen theerenen Intensiveinaintemealnc Omnrreneereten

2

eee 26. Automatic transmission fluid renewal ...............0.55ee Automatic transmission linkage lubrication ...2...........2.555 14 5 Auxiliary drivebelt(s) check and renewal ............-0-0.e0eeeee 4 sees eee-. Battery maintenance and charging ............ oe re 3DT.” be tinier ctie Gino c Oram Stale HUTCHINS BrakingisyStemicne chee me reperu-ne yeni tersreie er) orerroteria:wutteitele tyerere) brome oie aro n re BITE 2.4 Sinn’ SISTaNen Shoe INS SI Dian Cte sacl hae noeo cg) eNO Rc ON CP RP orc toneote reco ooCaNO nape aes ave ica S whee ery 5 Se Re ono Ooo rc occ udacanaen Godeomedeusbuasss0u GOTCHA TOMAPCUIOUL 4 downs po on ond lldmolo moon DAS Romwuos DyUlmo nar: Compression pressure at starter speed

62-0. eee eeeens ......--

eae et Ce SUILTLS We0° ee RP i Direction Of CrankSharlnotatlom) se ceces ssc ener

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aCe AC ee eas

Cylinder head Camshaft bearing diameter

0. cece ere teen eee eee .........-

Hydraulic tappet bore diameter

Cylinder head gasket thickness Cylinder head warp (maximum)

0... eee reece eee ees ........

6... eseer reese ........ ....---- 66. eee seer cere

Camshafts +e eee seer ees Camshaft bearing journal diameter .....--..--.2 Camshaft bearing journal-to-cylinder head running clearance ....... nooo Boone Jor Geinneneiciycileels. case op cous vgeos bb oopodomnoTe

Lubrication Engine oil type/specification .....-- see e eee tere e eee eee ees Engine cilicapacity cs. Asis: Mie cites at a aace er crete secre

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Suspension strut thrust bearing retaining nut

24 47

340 130 58 83 50

Tighten through further 90°

....................

59

Suspension strut upper mounting nut (renew) ..............-2006-

46

Suspension strut-to-steering knuckle pinch-bolt ..................

84

Rear suspension (Saloon/Hatchback) Antizrollibatiecrleenroetieae west enter thin at ‘ok iawn beeen eh Ati=rolllbarte linker ater aytrtycey atdys neat d)« are,| ekehiayopus ees CrossmembermimoOunting| DOltS tates sera cast vdeo ay ney conti ernpees ree eaters

25 35 120

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Front lower arm to knuckle and to crossmember

eae

.............+-5-

50

84

FAUOUNU tse cde nears) a eee beau decay ae dentate «.eee te ee Rear lower arimitoseroSSMeOMDClrian... sy stareins; se aces ears wees Rearlower armytoiknueklestain saps 2 heeds crags aerated). Se Ree Somes SUSDENSIONESINUE tO KMUCKIC 3 2 cielo rsrspeuel tole en co = 0-3 aeaENRREM Sete oy8

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Suspension strut upper mounting bolts ............. cece eee eee

27

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65 120 84

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Biss, :

Blown fuse (“Weekly checks” or Chapter 12). Faulty washer switch (Chapter 12).

‘

Instrument readings inaccurate or erratic Instrument readings increase with engine speed Faulty voltage stabiliser (Chapter 12).

Faulty washer pump (Chapter 12).

Washer pump runs for some time before fluid is emitted from jets

Fuel or temperature gauges give no reading

Faulty one-way valve in fluid supply hose (Chapter 12).

Faulty gauge sender unit (Chapter 3 or 4A).

Electric windows inoperative, or unsatisfactory in

Wiring open-circuit (Chapter 12). Faulty gauge (Chapter 12).

operation

Fuel or temperature gauges give continuous maximum reading

f

Faulty gauge sender unit (Chapter 3 or 4A). Wiring short-circuit (Chapter 12). Faulty gauge (Chapter 12).

Horn inoperative, or unsatisfactory in operation i Horn operates all the time

Horn push either earthed or stuck down (Chapter 12).

Horn cable-to-horn push earthed (Chapter 12).

Cable or cable connections loose, broken or disconnected (Chapter 12).

Faulty horn (Chapter 12). Horn emits intermittent or unsatisfactory sound

e

Windscreen/tailgate wipers inoperative, or

Wipers fail to operate, or operate very slowly Wiper blades stuck to screen, or linkage seized or binding (“Weekly checks” or Chapter fs 12). ‘

Cable or cable connections loose, broken or disconnected Faulty relay (Chapter 12). Faulty wiper motor (Chapter 12).

Window glass fails to move Blown fuse (Chapter 12).

Faulty relay (Chapter 12).

Central locking system inoperative, or

unsatisfactory in operation E

Complete system failure Blown fuse (“Weekly checks” or Chapter 12). Faulty relay (Chapter Faulty control module 12). (Chapter 11)

unsatisfactory in operation

(Chapter 12).

Window glass slow to move Regulator seized or damaged, or in need of lubrication (Chapter 11). Door internal components or trim fouling regulator (Chapter 11). Faulty motor (Chapter 11).

Faulty motor (Chapter 11).

Blown fuse (Chapter 12).

Blown fuse (“Weekly checks” or Chapter 12).

Panty switen (Chaprer i>

Broken or disconnected wiring or connections (Chapter 12).

Horn fails to operate

Cable connections loose (Chapter 12). Horn mountings loose (Chapter 12). Faulty horn (Chapter 12). ; ‘ . .

Window glass will only move in one direction

Broken or disconnected wiring or connections (Chapter 12). Latch locks but will not unlock, or unlocks but will not lock Bese dj dI ; roken or disconnected latch operating rods or levers (Chapter 11). Faulty relay (Chapter 12). Faulty control module (Chapter 11). One solenoid/motor fails to operate Broken or disconnected wiring or connections (Chapter 12).

Faulty operating assembly (Chapter 11).

Broken, binding or disconnected latch operating rods or levers

(Chapter 11).

Fault in door latch (Chapter 11).

Glossary of technical terms rere1s A

would tend to clog the radiator and coolant

ABS (Anti-lock brake system) A system, usually electronically controlled, that senses incipient wheel

lockup

during

braking

and

relieves hydraulic pressure at wheels that are about to skid.

passages and reduce cooling efficiency. Anti-seize compound A coating

that

reduces the risk of seizing on fasteners that are subjected to high temperatures, such as exhaust manifold bolts and nuts.

Air bag Aan inflatable bag hidden in the steering wheel (driver’s side) or the dash or glovebox (passenger side). In a head-on collision, the bags inflate, preventing the driver and front passenger from being thrown

Bearing The curved surface on a shaft or ina bore, or the part assembled into either, that permits relative motion between them with minimum wear and friction. Big-end bearing The bearing in the end of the connecting rod that’s attached to the crankshaft. Bleed nipple A valve on a brake wheel cylinder, caliper or other hydraulic component that is opened to purge the hydraulic system of air. Also called a bleed screw.

forward into the steering wheel or windscreen. Air cleaner A metal or plastic housing,

containing a filter element, which removes dust and dirt from the air being drawn into the engine. Air filter element The actual filter in an air cleaner system, usually manufactured from

pleated paper and requiring renewal at regular intervals.

Anti-seize compound

Asbestos A natural fibrous mineral with great heat resistance, commonly used in the composition of brake friction materials. Asbestos is a health hazard and the dust created by brake systems should never be inhaled or ingested. Axle A shaft on which a wheel revolves, or which revolves with a wheel. Also, a solid beam that connects the two wheels at one end of the vehicle. An axle which also transmits power to the wheels is known as a live axle.

Brake bleeding Procedure for removing air from lines of a hydraulic brake system. Brake disc The component of a disc brake that rotates with the wheels. Brake drum The component of a drum brake

Air filter Allen key A hexagonal wrench which fits into

a recessed hexagonal hole. Alligator clip A long-nosed spring-loaded

that rotates with the wheels.

metal clip with meshing teeth. Used to make temporary electrical connections. Alternator A component in the electrical

system which converts mechanical

energy

from a drivebelt into electrical energy to charge the battery and to operate the starting system, ignition system and_ electrical accessories.

Axle assembly Axleshaft

A single rotating shaft, on either

side of the differential,

which

delivers

power

from the final drive assembly to the drive wheels. Also called a driveshaft or a halfshaft.

B Alternator (exploded view)

Brake bleeding

Ball bearing An _ anti-friction bearing consisting of a hardened inner and outer race with hardened steel balls between two races.

Brake linings The friction material which contacts the brake disc or drum to retard the vehicle’s speed. The linings are bonded or riveted to the brake pads or shoes. Brake pads The replaceable friction pads that pinch the brake disc when the brakes are applied. Brake pads consist of a friction material bonded or riveted to a rigid backing plate. Brake shoe The crescent-shaped carrier to which the brake linings are mounted and which forces the lining against the rotating drum during braking. Braking systems For more information on

braking

systems,

consult

the

Haynes

volt

Automotive Brake Manual. Breaker bar A long socket wrench handle providing greater leverage. Bulkhead The insulated partition between the engine and the passenger compartment.

Anaerobic sealer A substance used to prevent bolts and screws from loosening. Anaerobic means that it does not require oxygen for activation. The Loctite brand is widely used. Antifreeze A substance (usually ethylene glycol) mixed with water, and added to a vehicle’s cooling system, to prevent freezing of the coolant in winter. Antifreeze also contains chemicals to inhibit corrosion and the formation of rust and other deposits that

Caliper The non-rotating part of a disc-brake assembly that straddles the disc and carries the brake pads. The caliper also contains the hydraulic components that cause the pads to pinch the disc when the brakes are applied. A caliper is also a measuring tool that can be set to measure inside or outside dimensions of an object.

Ampere (amp)

flow of electric

A unit of measurement for the

current.

One

amp

is the

amount of current produced by one acting through a resistance of one ohm.

C

Bearing

rere200 Glossary of technical terms Camshaft A rotating shaft on which a series of cam

lobes operate the valve mechanisms.

The camshaft may be driven by gears, by sprockets and chain or by sprockets and a

belt. Canister

A container

Catalytic converter A silencer-like device in the exhaust system which converts certain pollutants in the exhaust gases into less harmful substances.

in an evaporative

Crocodile clip See Alligator clip

D Diagnostic code Code numbers obtained by accessing the diagnostic mode of an engine management computer. This code can be used to determine the area in the system where a malfunction may be located. Disc brake A brake design incorporating a rotating disc onto which brake pads are

emission control system; contains activated charcoal granules to trap vapours from the fuel system.

squeezed. The resulting friction converts the

energy of a moving vehicle into heat. Double-overhead cam (DOHC) An engine that uses two overhead camshafts, usually one for the intake valves and one for the Catalytic converter

Canister

Carburettor

A device which mixes fuel with

air in the proper proportions to provide a desired power output from a spark ignition internal combustion engine.

Circlip A ring-shaped clip used to prevent endwise movement of cylindrical parts and shafts. An internal circlip is installed in a groove in a housing; an external circlip fits into a groove on the outside of a cylindrical piece such as a shaft. Clearance The amount of space between two parts. For example, between a piston and a cylinder, between a bearing and a journal, etc:

exhaust valves.

Drivebelt(s) accessories

The such

belt(s)

used

to

as the alternator,

drive water

pump, power steering pump, air conditioning compressor, etc. off the crankshaft pulley.

Coil spring A spiral of elastic steel found in various sizes throughout a vehicle, for example as a springing medium in the suspension and in the valve train. Compression Reduction in volume, and increase in pressure and temperature, of a gas, caused by squeezing it into a smaller

space.

Carburettor Castellated Resembling the parapets along the top of a castle wall. For example, a castellated balljoint stud nut.

Compression ratio The relationship between cylinder volume when the piston is at top dead centre and cylinder volume when the piston is at bottom dead centre. Constant velocity (CV) joint A type of universal joint that cancels out vibrations caused by driving power being transmitted through an angle. Core plug A disc or cup-shaped metal device inserted in a hole in a casting through

which core was removed when the casting was formed. Also known as a freeze plug or expansion plug. Crankcase The lower part of the engine

block in which the crankshaft rotates. Crankshaft The main rotating member, or

Accessory drivebelts Driveshaft

Any

shaft

used

Driveshaft

Drum brake A type of brake using a drumshaped metal cylinder attached to the inner surface of the wheel. When the brake pedal is

pressed, curved

brake shoes with friction

linings press against the inside of the drum to slow or stop the vehicle.

shaft, running the length of the crankcase,

Castellated nut Castor

In wheel alignment, the backward or

rearward at the top.

Crankshaft assembly

transmit

axleshafts on a front wheel drive vehicle.

with offset “throws” to which the connecting rods are attached.

forward tilt of the steering axis. Castor is positive when the steering axis is inclined

to

motion. Commonly used when referring to the

Drum brake assembly

Glossary of technical terms pere21 =

Feeler blade A thin strip or blade of hardened

EGR valve A valve used to introduce exhaust

gases into the intake air stream.

= =a \W

steel, ground to an exact thickness, used to check or measure clearances between parts.

electrode in a spark plug. Also refers to the spacing between the points in a contact

breaker assembly in a conventional pointstype ignition, or to the distance between the reluctor or rotor and the pickup coil in an electronic ignition.

Gasket

Any thin, soft material - usually cork,

cardboard, asbestos or soft metal - installed between two metal surfaces to ensure a good

seal. For instance, the cylinder head gasket

—=

seals the joint between cylinder head.

pone ae

the block

and the

EGR valve

Electronic control unit (ECU) A computer which controls (for instance) ignition and fuel injection systems, or an anti-lock braking system. For more information refer to the Haynes Automotive Electrical and Electronic

Systems Manual. Electronic Fuel Injection (EFl) A computer controlled fuel system that distributes fuel through an injector located in each intake port

of the engine. Emergency brake

A

braking

system,

independent of the main hydraulic system, that can be used to slow or stop the vehicle if the primary brakes fail, or to hold the vehicle stationary even though the brake pedal isn’t

depressed. It usually consists of a hand lever that actuates either front or rear brakes mechanically through a series of cables and linkages. Also Known as a handbrake or parking brake. Endfloat The amount of lengthwise movement between two parts. As applied to a crankshaft, the distance that the crankshaft can move forward and back in the cylinder block. Engine management system (EMS) A computer controlled system which manages the fuel injection and the ignition systems in

an integrated fashion. Exhaust manifold A part with several passages through which exhaust gases leave the engine combustion chambers and enter

the exhaust pipe.

Feeler blade Firing order The order in which the engine cylinders fire, or deliver their power strokes, beginning with the number one cylinder. Flywheel A heavy spinning wheel in which energy is absorbed and stored by means of momentum. On cars, the flywheel is attached

to

the

crankshaft

to

smooth

out

impulses. Free play The amount of travel before any action takes place. The “looseness” in a linkage, or an assembly of parts, between the

initial

application

of

force

and

actual

movement. For example, the distance the brake pedal moves before the pistons in the master cylinder are actuated. Fuse An electrical device which protects a circuit against accidental overload. The typical fuse contains a soft piece of metal which is calibrated to melt at a predetermined current flow (expressed as amps) and break the circuit. Fusible link A circuit protection device consisting of a conductor surrounded by heat-resistant insulation. The conductor is smaller than the wire it protects, so it acts as the weakest link in the circuit. Unlike a blown fuse, a failed fusible link must frequently be cut from the wire for replacement.

G Gap

Gasket

firing

The distance the spark must travel in

jumping from the centre electrode to the side

Gauge

An instrument panel display used to

monitor engine conditions. A gauge with a movable pointer on a dial or a fixed scale is an analogue gauge. A gauge with a numerical readout is called a digital gauge.

H Halfshaft

A rotating shaft that transmits

power from the final drive unit to a drive wheel, usually when referring to a live rear axle. Harmonic balancer A device designed to reduce torsion or twisting vibration in the crankshaft. May be incorporated in the crankshaft pulley. Also known as a vibration damper. Hone An abrasive tool for correcting small irregularities or differences in diameter in an engine cylinder, brake cylinder, etc. Hydraulic tappet A tappet that utilises hydraulic pressure from the engine’s lubrication system to maintain zero clearance (constant contact with both camshaft and valve stem). Automatically adjusts to variation in valve stem length. Hydraulic tappets also reduce valve noise.

Ignition timing The moment at which the spark plug fires, usually expressed in the

number

FE Fan clutch A viscous (fluid) drive coupling device which permits variable engine fan speeds in relation to engine speeds.

of crankshaft

degrees

before the

piston reaches the top of its stroke. Inlet manifold A tube or housing with passages through which flows the air-fuel mixture (carburettor vehicles and vehicles

Exhaust manifold

SEF

Adjusting spark plug gap

with throttle body injection) or air only (port fuel-injected vehicles) to the port openings in the cylinder head.

rere22 Glossary of technical terms J Jump start

Overhead cam (ohc) engine

Starting the engine of a vehicle

with a discharged or weak battery by attaching jump leads from the weak battery to a charged or helper battery.

L Load Sensing Proportioning Valve (LSPV) A brake hydraulic system control valve that works like a proportioning valve, but also takes into consideration the amount of weight

carried by the rear axle. Locknut A nut used to lock an adjustment nut, or other threaded component, in place. For example, a locknut is employed to keep the adjusting nut on the rocker arm in position.

Lockwasher A form of washer designed to prevent an attaching nut from working loose.

M

An engine with

the camshaft(s) located on top of the cylinder head(s). Overhead valve (ohv) engine An engine with the valves located in the cylinder head, but with the camshaft located in the engine block. Oxygen sensor A device installed in the engine exhaust oxygen content this information called a Lambda

manifold, which senses the in the exhaust and converts into an electric current. Also sensor.

Plastigage A thin strip of plastic thread, available in different sizes, used for measuring clearances. For example, a strip of Plastigage is laid across a bearing journal. The parts are assembled and dismantled; the width of the crushed strip indicates the clearance between

filaments into a hermetically-sealed one-piece unit. When a filament burns out or the lens cracks, the entire unit is simply replaced.

Serpentine drivebelt

A single, long, wide

accessory drivebelt that’s used on some newer vehicles to drive all the accessories, instead of a series of smaller, shorter belts.

Serpentine drivebelts are usually tensioned by

Plastigage

an automatic tensioner.

Propeller shaft The long hollow tube with universal joints at both ends that carries power from the transmission to the differential on front-engined rear wheel drive vehicles. Proportioning valve A hydraulic control valve which limits the amount of pressure to the rear brakes during panic stops to prevent wheel lock-up.

R a geared wheel

opened

up and laid flat).

When the steering wheel is turned, the pinion

turns, moving the rack to the left or right. This movement is transmitted through the track rods to the steering arms at the wheels. Radiator A liquid-to-air heat transfer device

designed to reduce the temperature of the

O-ring

S Sealant A liquid or paste used to prevent leakage at a joint. Sometimes used in conjunction with a gasket. Sealed beam lamp_ An older headlight design which integrates the reflector, lens and

Rack-and-pinion steering A steering system with a pinion gear on the end of the steering shaft that mates with a rack (think of

into a groove to provide the

secondary winding to the proper spark plug. Also, that part of an alternator which rotates

movement) of a gear or wheel as it’s rotated. The amount a shaft rotates “out-of-true.” The out-of-round condition of a rotating part.

O

is compressed sealing action.

inside the cap that connects the centre electrode and the outer terminals as it turns, distributing the high voltage from the coil

Phillips screw A type of screw head having a cross instead of a slot for a corresponding type of screwdriver.

Ohm The unit of electrical resistance. One volt applied to a resistance of one ohm will produce a current of one amp. Ohmmeter An instrument for measuring electrical resistance. O-ring A type of sealing ring made of a

special rubber-like material; in use, the O-ring

movement of the pushrod into a downward movement to open a valve. Rotor In a distributor, the rotating device

wheel, shaft and turbine wheel. Runout The amount of wobble (in-and-out

mounted between the body and the steering

NOx Oxides of Nitrogen. A common toxic pollutant emitted by petrol and diesel engines at higher temperatures.

valve

p

journal and bearing.

N

In an overhead

engine, the rocker arm converts the upward

inside the stator. Also, the rotating assembly of a turbocharger, including the compressor

MacPherson strut A type of front suspension system devised by Earle MacPherson at Ford of England. In its original form, a simple lateral link with the anti-roll bar creates the lower control arm. A long strut an integral coil spring and shock absorber - is knuckle. Many modern so-called MacPherson strut systems use a conventional lower A-arm and don’t rely on the anti-roll bar for location. Multimeter An electrical test instrument with the capability to measure voltage, current and resistance.

Rocker arm A lever arm that rocks on a shaft or pivots on a stud.

SS —

isRS SS WN

yi

ZO

Ry,

Serpentine drivebelt Shim Thin spacer, commonly used to adjust the clearance or relative positions between two parts. For example, shims inserted into or under bucket tappets control valve

clearances. Clearance is adjusted changing the thickness of the shim.

by

coolant in an internal combustion engine cooling system. Refrigerant Any substance used as a heat transfer agent in an air-conditioning system. R-12 has been the principle refrigerant for many years; recently, however, manufacturers

Slide hammer A special puller that screws into or hooks onto a component such as a shaft or bearing; a heavy sliding handle on the

have begun using R-134a, a non-CFC substance that is considered less harmful to

periphery of a wheel, shaped to engage with a chain or drivebelt. Commonly used to refer to

the ozone in the upper atmosphere.

shaft bottoms against the end of the shaft to knock the component free. Sprocket A tooth or projection on the

the sprocket wheel itself.

Glossary of technical terms rere2s Starter inhibitor switch On vehicles with an automatic transmission, a switch that

prevents starting if the vehicle is not in Neutral or Park.

Strut See MacPherson strut.

T Tappet A cylindrical component which transmits motion from the cam to the valve stem, either directly or via a pushrod and rocker arm. Also called a cam follower. Thermostat A heat-controlled valve that regulates the flow of coolant between the cylinder block and the radiator, so maintaining optimum engine operating temperature. A thermostat is also used in some air cleaners in

which the temperature is regulated. Thrust bearing The bearing in the clutch assembly that is moved in to the release

Toe-out The amount the front wheels are closer together at the rear than at the front. On front wheel drive vehicles, a slight amount of toe-out is usually specified. Tools For full information on choosing and using tools, refer to the Haynes Automotive Tools Manual. Tracer A stripe of a second colour applied to a wire insulator to distinguish that wire from another one with the same colour insulator. Tune-up A process of accurate and careful adjustments and parts replacement to obtain the best possible engine performance. Turbocharger A centrifugal device, driven by exhaust gases, that pressurises the intake air. Normally used to increase the power output from a given engine displacement, but can also be used primarily to reduce exhaust

emissions engine).

(as on

VW’s

“Umwelt”

Diesel

may be started, stopped, or regulated by a

movable part that opens, shuts, or partially obstructs one or more ports or passageways. A valve is also the movable part of such a device.

Valve clearance The clearance between the valve tip (the end of the valve stem) and the rocker arm or tappet. The valve clearance is

measured when the valve is closed. Vernier caliper A precision measuring instrument that measures inside and outside dimensions. Not quite as accurate as a micrometer, but more convenient. Viscosity The thickness of a liquid or its resistance to flow. Volt A unit for expressing electrical “pressure” in a circuit. One volt that will produce a current of one ampere through a resistance of one ohm.

levers by clutch pedal action to disengage the

clutch. Also referred to as a release bearing. Timing belt A toothed belt which drives the camshaft. Serious engine damage may result if it breaks in service. Timing chain A chain which drives the camshaft. Toe-in The amount the front wheels are

closer together at the front than at the rear. On.-rear wheel drive vehicles, a slight amount

U Universal joint or U-joint A double-pivoted connection for transmitting power from a driving to a driven shaft through an angle. A U-joint consists of two Y-shaped yokes and a cross-shaped member called the spider.

of toe-in is usually specified to keep the front wheels running parallel on the road by

V

offsetting other forces that tend to spread the

Valve A device through which the flow of liquid, gas, vacuum, or loose material in bulk

wheels apart.

W Welding

Various

processes

used

to join

metal items by heating the areas to be joined to a molten state and fusing them together. For more information refer to the Haynes Automotive Welding Manual. Wiring diagram A drawing portraying the components and wires in a vehicle’s electrical system, using standardised symbols. For more information refer to the Haynes Automotive Electrical and Electronic Systems

Manual.

REFe24 INdeEX Note: References throughout this index are in the form - “Chapter number” e “Page number”

A

discs - 9e4, 9e11 drums - 9°5

ABS

fluid - 0°12, 0°16, 1°20

hydraulic unit - 9°16 relay box - 9°18 wheel sensor - 9°18 Accelerator cable - 4Ae4 pedal - 4Ae6 Adhesive emblems - 11¢22 Aerial - 12°30

Air bag - 12°30 clock spring - 12¢31 control module - 12°31 Air cleaner assembly - 4Ae3 Air conditioning system - 3¢1 et seq check - 1°13 components - 3°13 precautions - 3e12 Air filter element - 1°19 Alternator - 5Ae4 brushes and voltage regulator - 5Ae5

Anti-roll bar - 10°9, 10°16, 10°19 Anti-theft alarm system - 12¢25 Antifreeze - 0°13, 0°16, 1¢2, 1°20, 362 Automatic transmission - 7B°1 et seq fault finding - 7Be1

fluid - 0°16, 1¢2, 1¢11, 1°20 linkage lubrication - 1°14 mountings - 7Be5 oil seals - 7Be3 overhaul - 7Be5

removal and refitting - 7Be3 Auxiliary drivebelt - 1¢9 Auxiliary warning system - 12°23

B Battery - 0°15, 1¢8, 5Ae2 Bearings, engine - 2C°23 Big-end bearings - 2C°23 Bleeding brakes - 9e14 clutch hydraulic system - 6°8 power steering - 10°26 Body electrical system - 12°1 et seq Body side-trim mouldings - 11°22 Bodywork and fittings - 11¢1 et seq Bonnet - 11¢7 check and lubrication - 1°17 lock - 11°98 release cable and lever - 11¢8 Boot lid - 11°16 lock components - 11°17 Brakes - 9¢1 et seq bleeding - 9°14 calipers - 9e3, 9¢10 check - 1°16

pads - 9e2, 98

pedal - 9°12 pedal-to-servo cross-link - 9°14 pipes and hoses - 9¢14 shoes - 9°5

Bulbs - 0¢15, 12¢2, 12¢10, 12014 Bumpers - 11¢5

C Calipers - 9°3, 9°10 Camshafts - 2Ae18, 2Be17 oil seals - 2A°17, 2Be17 Capacities - 1°2 Carpets - 11°3 Catalytic converter - 4Be8 CD player - 12¢29

Central locking - 11°21 Centre console - 11°26 Charging system - 5Ae71 et seq Clock - 12°21 Clutch - 6°1 et seq adjustment - 6¢2 bleeding - 6e8 cable - 6e3 components - 6e5

fluid - 0°12, 0°16 master cylinder - 6¢4 pedal - 1°14, 6e4 release bearing and slave cylinder - 6¢6 release shaft and bush - 6°7 Coil spring - 10°19 Component location - 1°4, 1°5, 1¢6 Compression test - 2A¢7, 2Be3 Conversion factors - REFe2 Coolant - 0°13, 0°16, 1¢2, 1°20, 3e2 pump - 3e8 Cooling fan - 3¢4 Cooling system - 3°1 et seq draining - 1°20

filling - 1¢21 flushing - 1°20 hoses - 3e3 switches and sensors - 3e5 Crankshaft - 2Ce18, 2Ce23, 2Ce25 oil seals - 2Ae29, 2Be26 pulley - 2A°12, 2Be11 Crossmember - 10°17, 10¢21 Cruise control system - 12°26 CV joint - 1¢15 gaiters - 8e4, 8e5 Cylinder block/crankcase - 2Ce19

Cylinder head - 2Ae22, 2Be20, 2Ce15 cover - 2Ae9, 2Be4

dismantling - 2C°14 reassembly - 2Ce16

Index Rere25

D Dents - 11¢3 Depressurising the fuel system - 4A¢2 Dimensions - REFe1 Discs - 9e4, 9e11 Door - 11°15 check and lubrication - 1¢17

handle and lock components - 11¢13 inner trim panel - 11¢8

window glass - 11°11 window regulator - 11°12 Draining the cooling system - 1°20 Driveshafts - 8°1 et seq gaiters - 1°15, 8¢4, 8e5 inspection and joint renewal - 8°6

removal and refitting - 8°2 Drums - 9¢5

= Electric cooling fan - 3¢4

Electric seats - 12°32 Electrical fault finding - 12¢3

Electrical switches - 3¢5, 12°6 Electrical system - 1°12 Emission control systems - 4Be1 et seq Engine removal and overhaul procedures - 2Ce1 et seq

bearings - 2Ce23 camshafts - 2Ae¢17, 2Ae18, 2Be17 compartment wiring check - 1¢13 compression test - 2Ae7, 2Be3

crankshaft - 2C°18, 2Ce23, 2Ce25 crankshaft oil seals - 2Ae29, 2Be26 crankshaft pulley - 2Ae12, 2Be11

cylinder block/crankcase - 2C°19 cylinder head - 2Ae®22, 2Be20, 2Ce14, 2Ce15, 2Ce16 cylinder head cover - 2Ae9, 2Be4 flywheel/driveplate - 2Ae30, 2Be27 initial start-up after overhaul - 2C «28

oil - 0°11, 0°16, 1¢2, 1¢7 oil cooler - 2Ae¢28, 2Be26 oil oil oil oil

level sensor - 2A®29 pressure warning light switch - 2A9®29, 2Be26 pump - 2Ae27, 2Be25 seals - 2Ae17, 2Ae29, 2Be17, 2Be26

overhaul - 2Ce13, 2Ce24 piston rings - 2Ce24

piston/connecting rod assemblies - 2C°17, 2Ce22, 2Ce26 sump - 2A925, 2Be24 timing belt - 1°25, 2Ae13 timing belt covers - 2Ae12, 2Be12

timing belt tensioner and toothed pulleys - 2Ae17 timing chains, tensioners and guides - 2Be14 won’t start - 0¢6 Engine/transmission mountings - 2Ae¢31, 2Be27

removal - 2C°4, 2Ce5, 2Ce11 Exhaust manifold - 2A°10, 2Be10 Exhaust system - 4Ae1 et seq

check - 1°16 description - 4Ae26

Expansion tank - 3°7 pressure cap check - 1°24 Exterior lights - 12°16

bulbs - 12°10 Exterior mirror and glass - 11°16

I Facia - 11°28 Fault finding - REFe12 electrical - 12¢3 Filling the cooling system - 1¢21 Fixed windows - 11°22

Fluids - 0¢16, 12 Flushing the cooling system - 1¢20 Flywheel/driveplate - 2A°30, 2Be27 Foglight beam alignment - 12°18 Fuel cut-off switch - 4A°10 Fuel filler flap and release cable - 11°30 Fuel filter - 1°24 Fuel gauge sender unit - 4A°7 Fuel injection system

checking and fault diagnosis - 4A¢14 components - 4A¢®20 description - 4Ae10 Fuel injectors - 4A°23, 4A°24 Fuel lines - 1¢16, 4Ae3 Fuel pressure check - 4A°6 Fuel pump - 4Ae6, 4Ae7 Fuel system - 4A¢1 et seq depressurisation - 4Ae¢2 Fuel tank - 4Ae¢8 Fuses - 0e15, 12¢4

G Gaiters driveshaft - 1°15, 8e4, 8e5 power steering gear - 10°26 Gear lever - 7Ae2 Gearchange linkage - 7Ae2 Glossary of technical terms - REFe19

Glovebox - 11°28

H Handbrake cables - 9°20 lever - 9°20

Handle - 11¢13 Headlights - 12°16 beam alignment - 12°18 levelling motor - 12°19 Heater/air conditioning controls - 3¢11 Heater/ventilation components - 3¢9 Heating system - 3°71 et seq Horn - 12¢21

HT coil - 5Be2 Hub and bearings - 10¢7, 10°13, 10¢18 Hydraulic pipes and hoses - 9¢14 Hydraulic system bleeding - 9°14

REFe26 INdeX

p Ignition system - 5Be1 et seq coil - 5Be2 module - 5Be3

timing - 5Be3 Injectors - 4Ae23, 4Ae24 Inlet manifold - 2A°9, 2Be7 Instrument panel - 12°19 Instruments - 12¢20

Interior light bulbs - 12¢14 Interior mirror - 11°16 Interior trim panels - 11¢8, 11°25 Introduction - 0«4

J Jacking - REFe5 Jump starting - 0°7

Pads - 9e2, 9e8 Parking sensor system - 12°31 Piston rings - 2C°24 Piston/connecting rod assemblies - 2C°17, 2C #22, 2C°26 Pollen filter - 1°18 Positive Crankcase Ventilation (PCV) system - 1°19 Power steering bleeding - 10°26

fluid - 0¢11, 0¢16 fluid cooler - 10¢28 gear gaiters - 10°26 pump - 10°26 Pressure-control relief valve - 9°16 Punctures - 0¢8

R

L

Radiator - 3¢7

Leaks - 0e9, 1°12 Lower arm - 10°10, 10¢12, 10°16, 10°20 Lubricants - 0°16, 1¢2

Radio aerial - 12°30 Radio/cassette player - 12¢28 anti-theft system - REFe5 power amplifier - 12°29 Reference - REFe1 et seq Relays - 12¢4 Repair procedures - REFe4 Reversing light switch - 7Ae¢4

M Main bearings - 2Ce23 Maintenance schedule - 1¢3 Major body damage - 11¢5

Manifolds - 2Ae9, 2A°10, 2Be7, 2Be10 Manual transmission - 7A¢1 et seq mounting - 7Ae8

oil - 0°16, 192, 1014 oil seals - 7Ae4

overhaul - 7Ae8 removal and refitting - 7A°4 Master cylinder - 6¢4, 9e11

MOT test checks - REFe8

O Oil cooler - 2A928, 2Be26 engine - 0°11, 0°16, 1¢2, 1°7 filter - 1¢7 level sensor - 2Ae29 manual transmission - 0¢16, 1¢2, 1°14 pressure warning light switch - 2Ae29, 2Be26

pump - 2Ae27, 2Be25 Oil seals automatic transmission - 7Be3 engine - 2Ae17, 2Ae29, 2Be17, 2Be26 manual transmission - 7A®4 Overhead console - 11°28

electric cooling fan - 3°4

grille -

11¢7

Road test - 1°17 Roadside Repairs - 0°6 et seq Roadwheels - 1°14, 1°17 Rocker arms - 2Be17 Roll-over valves - 4A¢9 Routine maintenance and servicing - 1¢2 et seq Rust - 11¢3

S Safety first! - 0¢5 Satellite navigation system - 12°31 Scratches - 11¢3 Screen washer fluid - 0e12 Seat belts - 1°14, 11023 Seats - 11°22, 12e32 Selector assembly - 7Be2 cable - 7Be2 lever position sensor - 7Be3 Sensors - 3¢5 Servicing see Routine maintenance Shock absorber - 10°19 Shoes - 9¢5 Short-circuit - 12¢4 Spare parts - REFe3 Spark plugs - 1¢22, 1024

INdex REFe27 Speakers - 12¢30 Speedometer drive cable - 12°20 pinion - 7Ae4, 7Be2 Starter motor - 5A¢6, 5Ae7

Starting problems - 0e6 Starting system - 5Ae1 et seq

Steering - 10°1 et seq angles - 10°29 check - 1°14 column - 10°22, 10e24 gear - 10°24, 10°25

knuckle and hub assembly - 10¢6 wheel - 10°21 Stop-light switch - 9e20 Sump - 2Ae25, 2Be24 Sunroof - 11°22 Suspension - 10°71 et seq check - 1°14 crossmember - 10°17, 10°21 knuckle - 10°13, 10¢18 lower arm - 10°10, 10°12, 10°16, 10°20

strut - 10°7, 10¢8, 10°14, 10¢16 tie-bar - 10°17, 10¢21 upper arm - 10°20

7

Switches - 3e5, 12¢6

Tailgate - 11°18 lock - 11°19 support strut - 11°19 washer system components - 12°28 wiper motor assembly - 1223

TCS inhibitor switch - 9¢19 throttle actuator - 9¢19 TDC for No 1 piston - 2Ae8, 2Be4 Thermostat - 3¢3 Tie-bar - 10°17, 10¢21 Timer module - 12¢4

Timing belt - 1°25, 2A9e13 covers - 2Ae®12, 2Be12 tensioner and toothed pulleys - 2Ae17 Timing chain - 2Be14 Tools - REFe6 Towing - 0°9 Track rod end - 10°29 Trim panels - 11°8, 11°25 Trip computer module - 12°23 Tyres - 0¢14 pressures - 0°16

U Underbody check - 1¢5, 1°6, 1°16 Underbonnet check - 0°10, 1¢4, 1°12 Upholstery - 11¢3 Upper arm - 10°20

V V6 (Duratec) engine in-car repair procedures - 2Be1 et seq Vacuum servo unit - 9¢15 Valve clearances - 2Ae20 Vehicle identification - REFe3 Vehicle support - REFe5 Ventilation system pollen filter - 1°18

W Washer fluid - 0°12 Water pump - 3¢8 Weekly checks - 0°10 et seq

Weights - REFe1 Wheel alignment - 10°29 arch liner - 11¢29

changing - 0°8 cylinder - 9e7 Window glass - 11¢11 regulator - 11°12 Windscreen - 11°22

washer system components - 12¢28 wiper motor and linkage - 12°22 Wiper arms - 12¢22 blades - 0°13 Wiring diagrams - 12°33 et seq

Working facilities - REFe6

Z Zetec engine in-car repair procedures - 2A¢1 et seq

Haynes Manuals - The Complete List Title

Book No.

Title

Fiat Tipo (88 - 91) E to J

Book No.

1625

Alfa Romeo Alfasud/Sprint (74 - 88) uptoF Alfa Romeo Alfetta (73 - 87) up toE ALFA ROMEO

0292 — Fiat Uno (83 - 95) up to M 0531 ‘Fiat X1/9 (74 - 89) up toG

Audi 80 (72 - Feb 79) up to T Audi 80, 90 (79 - Oct 86) up to D & Coupe

0207

Ford Capri Il (& Ill) 1.6 & 2.0 (74 - 87) up toE 0283 Ford Capri II (& Ill) 2.8 & 3.0 (74 - 87) up toE 1309

(81 - Nov 88) up to F Audi 80, 90 (Oct 86 - 90) D to H & Coupe

0605

Ford Cortina Mk IV (& V) 1.6 & 2.0 (76 - 83) up to A 0343 Ford Escort (75 - Aug 80) up to V 0280

(Nov 88 - 90) F to H Audi 100 (Oct 82 - 90) up to H & 200

1491

(Feb 84 - Oct 89) A to G

0907 — Ford Escort Mk Il Mexico, RS 1600 & RS 2000

Audi 100 & A6 Petrol & Diesel

(May 91 - May 97) H to P Audi Ad (95 - Feb 00) M to Vv

3504 3575

Austin/MG/Rover Maestro 1.3 & 1.6 (83 - 95) up to M Austin/MG Metro (80 - May 90) up to G 0718 Austin/Rover Montego 1.3 & 1.6 (84 - 94) A to L1066 Austin/MG/Rover Montego 2.0 (84 - 95) Ato M 1067 Mini (59 - 69) up to H 0527 Mini (69 - Oct 96) up to P 0646 Austin/Rover 2.0 litre Diesel Engine (86 - 93)

CtoL BEDFORD Bedford CF (69 - 87) up to E Bedford/Vauxhall Rascal & Suzuki Supercarry (86 - Oct 94) C to M

1857

BMW 316, 320 & 320i (4-cyl) (75 - Feb 83) up to Y BMW 320, 320i, 323i & 325i (6-cyl) (Oct 77 - Sept 87) up to E BMW 3-Series (Apr 91 - 96) H to N BMW 3- & 5-Series (sohc) (81-91) uptoJ BMW 520i & 525e (Oct 81 - June 88) uptoE BMW 525, 528 & 528i (73 - Sept 81) up toX CITROEN Citroén 2CV, Ami & Dyane (67 - 90) up to H Citroén AX Petrol & Diesel (87 - 97) D to P Citroén BX (83 - 94) Ato L Citroén C15 Van Petrol & Diesel (89 - Oct 98) F to S Citroén CX (75 - 88) up to F Citroén Saxo Petrol & Diesel (96-98) NtoS Citroén Visa (79 - 88) up to F Citroén Xantia Petrol & Diesel (93 - 98) KtoS Citroén XM Petrol & Diesel (89-98)GtoR Citroén ZX Diesel (91 - 93) J to L Citroén ZX Petrol (91 - 94) H to M Citroén 1.7 & 1.9 litre Diesel Engine (84 - 96) A to COLT Colt/Mitsubishi 1200, 1250 & 1400 (79 - May 84) up to A FIAT Fiat 500 (57 - 73) up to M Fiat Cinquecento (93 - 98) K to R Fiat Panda (81 - 95) up to M Fiat Punto Petrol & Diesel (94 - Oct 99) LtoV Fiat Regata (84 - 88) A to F

0276 0815 3210 1948 1560 0632 0196 3014 0908 3509 0528 3506 0620 3082 3451 1922 1881 N1379

0600

Ford Escort (Sept 80 - Sept 90) up to H Ford Escort & Orion (Sept 90 -'97) H to P

0686 1737

(75 - 80) up to W

0735

Ford Fiesta (76 - Aug 83) up to Y Ford Fiesta (Aug 83 - Feb 89) A to F

0334 1030

Ford Fiesta (Feb 89 - Oct 95) F to N

1595

Ford Fiesta Petrol & Diesel (Oct 95 - 97) Nto R Ford Granada (Sept 77 - Feb 85) up to B Ford Granada & Scorpio (Mar 85-94) BtoM Ford Ka (96 - 99) P to T Ford Mondeo Petrol (93 - 99) K to T Ford Mondeo Diesel (93 - 96) L to N Ford Orion (83 - Sept 90) up to H Ford Sierra 4 cyl. (82 - 93) up to K Ford Sierra V6 (82 - 91) up to J Ford Transit Petrol (Mk 2) (78 - Jan 86) up to C Ford Transit Petrol (Mk 3) (Feb 86 - 89)C toG Ford Transit Diesel (Feb 86 - 99) C to T Ford 1.6 & 1.8 litre Diesel Engine (84 - 96) AtoN Ford 2.1, 2.3 & 2.5 litre Diesel Engine (77 - 90) up to H FREIGHT ROVER Freight Rover Sherpa (74 - 87) up to E HILLMAN Hillman Avenger (70 - 82) up to Y

3397 0481 1245 3570 1923 3465 1009 0903 0904 0719 1468 3019 1172

Honda Accord (76 - Feb 84) up toA Honda Civic (Feb 84 - Oct 87) Ato E Honda Civic (Nov 91 - 96) J to N HYUNDAI :

0351 1226 3199

Jaguar E Type (61 - 72) up to L

0140

Jaguar MkI & II, 240 & 340 (55 - 69) up to

0098

1606 0463 0037

Jaguar XJ6, XJ & Sovereign; Daimler Sovereign

(68 - Oct 86) up to D Jaguar XJ6 & Sovereign (Oct 86 - Sept 94) DtoM

Daimler Double Six (72 - 88) up to F

Book No.

Land Rover Series Il, IIA & III Petrol

(58 - 85) up to C

0314

Mazda 323 (Mar 81 - Oct 89) up to G Mazda 323 (Oct 89 - 98) Gto R Mazda 626 (May 83 - Sept 87) up to E Mazda B-1600, B-1800 & B-2000 Pick-up (72 - 88) up to F MERCEDES BENZ

1608 3455 0929 0267

Mercedes-Benz 190, 190E & 190D

Petrol & Diesel (83 - 93) A to L Mercedes-Benz 200, 240, 300 Diesel (Oct 76 - 85) up to C Mercedes-Benz 250 & 280 (68-72) uptoL Mercedes-Benz 250 & 280 (123 Series) (Oct 76 - 84) up to B Mercedes-Benz 124 Series (85 - Aug 93) C to K MGB (62 - 80) up to W MG Midget & AH Sprite (58 - 80) up to W MITSUBISHI Mitsubishi Shogun & L200 Pick-Ups (83 - 94)

3450 1114 0346 0677 3253 0111 0265

up to M

Morris Ital 1.3 (80 - 84) up to B Morris Minor 1000 (56 - 71) up to K Nissan Nissan Nissan Nissan Nissan

Bluebird (May 84 - Mar 86) A to C Bluebird (Mar 86 - 90) C toH Cherry (Sept 82 - 86) up to D Micra (83 - Jan 93) up to K Micra (93 - 99) K to T

1223 1473 1031 0931 3254

Nissan Primera (90 - Aug 99) H to T

1851

Nissan Stanza (82 - 86) up to D Nissan Sunny (May 82 - Oct 86) up to D Nissan Sunny (Oct 86 - Mar 91) D to H Nissan Sunny (Apr 91 - 95) H to N OPEL Opel Ascona & Manta (B Series) (Sept 75 - 88) up to F Opel Ascona (81 - 88) (Not available in UK see Vauxhall Cavalier 0812) Opel Astra (Oct 91 - Feb 98)

0824 0895 1378 3219

0316 3215

(vot available in UK see Vauxhall Astra 1832) 3156 Opel Calibra (90 - 98)

0242

(See Vauxhall/Opel Calibra Book No. 3502)

Opel Corsa (83 - Mar 93) 3261

Jaguar XJ12, XJS & Sovereign;

(Not available in UK see Vauxhall Nova 0909)

3160

Opel Corsa (Mar Q3- 97)

0478 = (Not available in UK see Vauxhall Corsa 1985) 1943

Lada 1200, 1300, 1500 & 1600 (74-91) up tod

0413 —Qpel Kadett (Oct 84 - Oct 91) (Not available in 1610

3159

Opel Frontera Petrol & Diesel (91 - 98)

Jeep Cherokee Petrol (93 - 96) K to N

Lada Samara (87 - 91) D to J 0090 3501 0793 3251 1167

0923 0273

Title

(See Vauxhall/Opel Frontera Book No. 3454)

Opel Kadett (Nov 79 - Oct 84)

0634

UK see Vauxhall Astra & Belmont 1136)

3196

Opel Omega & Senator (86 - 94) (Not available

Land Rover 90, 110 & Defender Diesel (83 - 95) up toN3017 ~—in UK see Vauxhall Carlton & Senator 1469) Land Rover Discovery Diesel (89-95)GtoN 3016 Opel Omega (94 - 99) Land Rover Series IIA & III Diesel (See Vauxhall/Opel Omega Book No. 3510) (58 - 85) up to C 0529 Opel Rekord (Feb 78 - Oct 86) up to D

3157

0543

Title Opel (Not Opel (Not

Book No

Title

Vectra (Oct 88 - Oct 95) available in UK see Vauxhall Cavalier 1570) 3158 Vectra Petrol & Diesel (95 - 98) available in UK see Vauxhall Vectra 3396) 3523

SEAT

Peugeot 106 Petrol & Diesel (91-98) JtoS Peugeot 205 (83 - 95) Ato N

1882 0932

Book No

Seat Ibiza & Cordoba Petrol & Diesel Seat Ibiza & Malaga (85 - 92 ) B to K

3571 1609

Skoda Estelle (77 - 89) up to G Skoda Favorit (89 - 96) F to N

0604 1801

(Oct 93 - Oct 99) L to V

Peugeot 305 (78 - 89) up to G

0538 — Skoda Felicia Petrol & Diesel (95-99)

Peugeot 306 Petrol & Diesel (93-99) KtoT

3073

Peugeot 309 (86 - 93) C to K

1266 =Subaru 1600 & 1800 (Nov 79-90) uptoH

Peugeot 406 Petrol (88 96) Eto

MtoT

3505

QT

1c eee 2

Peugeot 405 Diesel (88 - 96) E to N 3198 — Suzuki SJ Series, Samurai & Vitara (4-cyl) Peugeot 406 Petrol & Diesel (96-97) NtoR 3394 (82-97) uptoP Peugeot 505 (79 - 89) up to G 0762 Suzuki Supercarry (86 - Oct 94) C to M TALBOT Peugeot 1.7/1.8 & 1.9 litre Diesel Engine (82 - 96) up to N 0950 Talbot Alpine, Solara, Minx & Rapier (75 - 86) up to Peugeot 2.0, 2.1, 2.3 & 2.5 litre Diesel Engines Talbot Horizon (78 - 86) up to D (74 - 90) up to H Talbot Samba (82 - 86)up to D __ TOYOTA Porsche 911 (65 - 85) up to C Toyota Carina E (May 92 - 97) J to P Porsche 924 & 924 Turbo (76 - 85) up to C Toyota Corolla (Sept 83 - Sept 87) Ato E PROTON 4 Toyota Corolla (80 - 85) up to C Proton (89 - 97) F to P Toyota Corolla (Sept 87 - Aug 92) E to K RANGE ROVER Toyota Corolla (Aug 92 - 97) K to P Range Rover V8 (70 - Oct 92)up to K Toyota Hi-Ace & Hi-Lux (69 - Oct 83) up toA RELIANT : TRIUMPH Reliant Robin & Kitten (73 83) - up to A Triumph Acclaim (81 - 84) up to B RENAULT Triumph GT6 & Vitesse (62 - 74) up to N Renault 5 (Feb 85 - 96) B to N 1219 Triumph Spitfire (62 - 81) up to X Renault 9 & 11 (82 - 89) up to F 0822 Triumph Stag (70 - 78) up to T Renault 18 (79 - 86) up to D 0598 Triumph TR7 (75 - 82) up to Y Renault 19 Petrol (89 - 94) F to M 1646 VAUXHALL Renault 19 Diesel (89 - 95) F to N 1946 Vauxhall Astra (80 - Oct 84) up to B Renault 21 (86 - 94) C toM 1397 Vauxhall Astra & Belmont Renault 25 (84 - 92) B to K 1228 (Oct 84 - Oct 91) Bto J Renault Clio Petrol (91 - May 98) H to R 1853 Vauxhall Astra (Oct 91 - Feb 98) J to R Renault Clio Diesel (91 - June 96) H to N 3031 Vauxhall/Opel Calibra (90 - 98) G to S Renault Espace Petrol & Diesel (85 - 96) C to N 3197 Vauxhall Carlton (Oct 78 - Oct 86) up to D

0995

1942 3015

D 0337 0473 0823 3256 1024 0683 1683 3259 0304 0792 0112 0113 0441 0322 0635 1136 1832 3502 0480

Renault Fuego (80 - 86) up to C

0764

Renault Laguna Petrol & Diesel (94 - 96) L to P Renault Mégane & Scénic Petrol & Diesel

Vauxhall Cavalier 1600, 1900 & 2000 $252 = (75 - July 81) up to W Vauxhall Cavalier (81 - Oct 88) up to F

0315 0812

(96 - 98) N toR

3395

Vauxhall Cavalier (Oct 88 - 95) F to N

1570

Vauxhall Chevette (75 - 84) up to B

0285

Vauxhall Corsa (Mar 93 - 97)KtoR Vauxhall/Opel Frontera Petrol&Diese

1985

(91 - Sept 98) J to S Vauxhall Nova (83 - 93) up to K

3454 0909

Rover 213 & 216 (84 - 89) AtoG Rover 214 & 414 (89 - 96) GtoN

1116 1689

Rover 216 & 416 (89 - 96) G to N 1830 Rover 211, 214, 216, 218 & 220 Petrol & Diesel

(Dec95 - 98) NtoR Rover 414, 416 & 420 Petrol & Diesel

Vauxhall Carlton & Senator (Nov 86 - 94) D to L 1469

3453

Rover 618, 620 & 623 (93 - 97) K to P Rover 820, 825 & 827 (86 - 95) D toN

3257 1380

Vauxhall/Opel 1.5, 1.6 & 1.7 litre

Rover 3500 (76 - 87) up to E

0365 —Volkswagen Beetle 1200 (54 - 77) up to S

Rover Metro, 111 & 114 (May 90-96) GtoN

1711

SAAB Saab 90, 99 & 900 (79 - Oct 93) up to L Saab 900 (Oct 93 - 98) Lto R Saab 9000 (4-cyl) (85 - 95) C to N

0765 3512 1686

Diesel Engine (82 - 96) up to N | AY Yea

Volkswagen Polo Hatchback Petrol & Diesel

(94 - 99) Mto S 3500 Volkswagen Scirocco (82 - 90) up to H 1224 Volkswagen Transporter 1600 (68 - 79) up to V 0082 Volkswagen Transporter 1700, 1800 & 2000 (72 - 79) up to V 0226 Volkswagen Transporter (air-cooled) (79 - 82) up to Y 0638 Volkswagen Transporter (water-cooled) (82 - 90) up to H 3452 VOLVO Volvo 142, 144 & 145 (66 - 74) up to N 0129 Volvo 240 Series (74 - 93) up to K 0270 Volvo 262, 264 & 260/265 (75-85) uptoC 0400 Volvo 340, 343, 345 & 360 (76-91) uptoJ 0715 Volvo 440, 460 & 480 (87 - 97) D to P 1691 Volvo 740 & 760 (82 - 91) up to J 1258 Volvo 850 (92 - 96) J to P 3260 Volvo 940 (90 - 96) H to N 3249 Volvo S40 & V40 (96 - 99) N to V 3569 Volvo $70, V70 & C70 (96-99) PtoV __ 3573 YUGO/ZASTAVA Yugo/Zastava (81 - 90) up to H 1453 AUTOMOTIVE TECHBOOKS Automotive Brake Manual 3050 Automotive Carburettor Manual 3288 Automotive Diagnostic Fault Codes Manual 3472 Automotive Diesel Engine Service Guide 3286 Automotive Disc Brake Manual 3542 Automotive Electrical and Electronic Systems Manual 3049 Automotive Engine Management and Fuel Injection

3399 — Vauxhall/Opel Omega (94 - 99) L to T 3510 Vauxhall Vectra Petrol & Diesel (95 - 98) N to R 3396

(May 95 - 98) M to R

Title Book No. Volkswagen Golf & Jetta Mk 1 1.1 & 1.3 (74 - 84) up toA 0716 Volkswagen Golf, Jetta & Scirocco Mk 1 1.5,1.6 & 1.8 (74 - 84) up to A 0726 Volkswagen Golf & Jetta Mk 1 Diesel (78 - 84) up to A 0451 Volkswagen Golf & Jetta Mk 2 (Mar 84 - Feb 92) A to J 1081 Volkswagen Golf & Vento Petrol & Diesel (Feb 92 - 96) J to N 3097 Volkswagen LT vans & light trucks (76 - 87) up to E 0637 Volkswagen Passat & Santana (Sept 81 - May 88) up to E 0814 Volkswagen Passat Petrol & Diesel (May 88 - 96) E to P 3498 Volkswagen Polo & Derby (76 - Jan 82) up to X 0335 Volkswagen Polo (82 - Oct 90) up to H 0813 Volkswagen Polo (Nov 90 - Aug 94) H to L 3245

1222

0036

Volkswagen Beetle 1300 & 1500 (65 - 75) up to P 0039 Volkswagen Beetle 1302 & 1302S (70 - 72) uptoLl 0110 Volkswagen Beetle 1303, 1303S & GT 0159 (72-75) up toP

Systems Manual

3344

Automotive Gearbox Overhaul Manual

3473

Automotive Service Summaries Manual

3475

Automotive Timing Belts Manual — Austin/Rover 3549 Automotive Timing Belts Manual - Ford 3474 Automotive Timing Belts Manual — Peugeot/Citroén 3568 Automotive Timing Belts Manual — Vauxhall/Opel3577 Automotive Welding Manual 3053 In-Car Entertainment Manual (3rd Edition) 3363 OTHER TITLES gene Haynes Diesel Engine Systems & Data Book (91 -00) 3548 Haynes Petrol Models Data Book (94 - 00) 3718 CLO9.04/00

All the products featured on this page are available through most motor accessory shops, cycle shops Elale| book stores. Our policy (0) continuous updating and development means that titles are being constantly added to the range. For up-to-date information on our complete list of titles, please telephone: (UK) +44 1963 440635 « (USA) +1 805 498 6703 « (France) +33 1 47 78 50 50 ¢ (Sweden) +46 18 124016 ¢ (Australia) +61 3 9763 8100

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